17
Setup Guide and component Identification
Section 2
C
INSTALLING THE WIRE SPOOL
4
5
-
To thread the wire from the spool properly through the wire feeder into the gun:
1.
Install the MIG gun as instructed in
“
To install the MIG gun (torch)
”
above. Loosen the top idler roller tensioner, rotating the black tensioner knob counter
-
clockwise.
2.
Flip the tensioner down, toward you, releasing the carrier arm that holds the top drive rolls.
3.
Raise the carrier arm up. Inspect the drive rolls to make sure that each roller
’
s groove size matches the wire diameter. Also make sure correct type of drive rollers are used. i.e.
Flux
-
Core drive rolls use special serrated rolls. (Top driven rollers do not have grooves and are not to be removed).
4.
Reversal of the lower drive roll to select the right size drive groove may be necessary.
To reverse the lower drive roll:
Remove the retaining screw with the black plastic secur-
ing the lower drive roll. Remove the outer ring of the drive roll and flip the drive roll over. The drive roll is actually made of two pieces. Hold the inner assembly of the drive roll on
with one finger (to prevent it from slipping off the shaft), while slipping the outer
“
rim
”
of the drive roll off with the other hand.
NOTE: Both inner and outer parts of the assembly
have locating keys.
To reinstall: Line up the outer rim of the drive roll keyway with the locating key. Reassemble and tighten. Before finishi ng assembly, make
sure the locating keys are fully in place and have not slipped out of their respective key ways during assembly. Lightly coat the inner mating surfaces with light weight lubricant
oil if necessary to prevent future seizure. Do not lubricate the surfaces of the drive rolls or wire slipping and erratic feeding may result.
5.
Follow instructions above:
“
To Load Spool of Wire.
”
Make sure the spool of wire is loaded correctly so that the wire unrolls from the bottom of the spool (counter
-
clockwise).
Thread the wire into the coiled guide and over the matching groove in lower drive roll. Thread the wire fully through until it threads into the gun section
4”
-
6”.
Lower the upper
drive roll into contact with the lower drive roll while keeping the wire securely fixed in the groove. If needed, use a screwdriver with a fine blade or small pick to keep the welding
wire from moving out of the grooves until step 6 is completed. Recheck once again that the correct drive groove has been selected.
6.
Raise drive roll tensioner back into place. Tighten it slightly so the wire will feed. Make a note of the visible markings on tensioner handle for future reference.
7.
Remove the contact tip from the torch. (Not Shown).
Hold the torch cable and gun as straight as possible, in direct line with the unit so feeding of the wire through
the gun liner is smooth and easy. Press the gun trigger to feed wire until the wire exits the end of the torch. Reinstall the contact tip over the wire over the wire and tighten it.
8.
To prevent bird nesting or slipping of the wire, adjust the tensioner clockwise until the drive rolls will not slip when the wire comes into contact with a hard surface. The wire will
curl up on end while feeding under power. If you over
-
tension the wire, you will increase the chances of bird nesting of the wire (balling up of the wire or curling of the wire
around the drive rolls), so it is best to tighten just until wire stops slipping and is able to curl up. Extra tension can deform wire and prematurely wear the drive rolls. Slowing of
the feeder may result as well.
Remember not to test on any metal attached to the work clamp to prevent the wire from arcing while performing this test.
1
4
5
A
B
C
To load the spool of wire:
1.
Loosen and remove the hand nut (if present) on the spool carrier by
turning it counter
-
clockwise.
2.
Align the locating pin with the hole on the wire spool (if present).
3.
Slide spool onto the shaft. Make sure wire is unwinding from the
bottom of the spool.
4.
Adjust de
-
spooling tension by turning tensioner located under the hand
nut on the spool carrier.
5.
Lightly spin the spool. If it free
-
wheels more than 1/4 turn, tighten the
tensioning hex nut slightly, 1/4 to 1/2 turn and retest the free wheel. If it
does not free
-
wheel at all, loosen the nut until it free wheels 1/4 turn.
6.
Reinstall the hand nut (if equipped) so the spool is retained securely.
7.
Locate the end of the wire and clip the bent end of the wire so that it will
feed through the wire feed mechanism smoothly. Carefully hold the
spool of wire with one hand so the wire will not de
-
spool. Proceed to
instructions listed below:
“
To thread wire from the spool properly
through the feeder.
”
8
Bottom Drive Roll Siz-
ing
(See side for stamped size)
.6mm=.023
”
-
.025”
.8mm=.030
”
.9mm=.035
”
1.0mm=.040
”
1.2mm=.045
”
To change the polarity of the MIG gun:
Unscrew the screw from the (+) terminal. Loosen
top screw, do not remove completely. Swing copper buss bar up so the hole in the
(
—
)
terminal
lines up with the hole in the buss bar. Reinstall screw into the ( —
)
terminal.
Tighten both screws.
To install the MIG gun (torch).
A.
Align pins on the torch connector with the feeder receptacle.
B.
Fully engage the connector into the receptacle on the welder.
C.
Twist the plastic hand nut on the connector clockwise until it is
snug.
Tighten by hand only or damage may result.
3
2
6
